Aluminum Extrusion Technology Seminar (1996)

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VOLUME I – Brief Contents

Extrusion Process and Equipment
Billet Process and Equipment

Creativity and Technology

EXTRUSION PROCESS AND EQUIPMENT

The Effect of Cooling Rate After Homogenization and Billet Preheating Practice on Extrudability and Section Properties Part 1: Extrudability and Mechanical Properties
Metallurgical Speed Limitations During the Extrusion of Al-Mg-Si Alloys

Equipment

A Paradigm Shift in Aluminum Extrusion Processes Due to Long Metal Handling
The Ten-Second Dead Cycle
How to Operate Extrusion Presses Well

Process and Process Control

Isothermal and Isopressure Extrusion – Results of Process Optimization in Various Extrusion Plants
Improvement of Aluminum Extrusion Profiles for Architecture
Theoretical and Practical Considerations for the Applications of “Fuzzy Logic” in the Aluminum Extrusion Industry
Surface Defects on 6XXX Alloy Extrusions
Flow Formulation FE Metal Forming Analysis with Boundary Friction Via Penalty Function
Isothermal Extrusion of Aluminum Alloys by Employing Force-Ram Speed Feedback
A New Measurement and Control System for Isothermal Extrusion
The Importance of a Powerful Press Control System to Attain and Improve Quality and Delivery Performance
Increasing Extrusion Plant Productivity and Quality
Integration of the Ageing Cycle into an Automated Extrusion Line
Modernizing the Extrusion Press and Handling System: Adapting New Technologies to Older Plants

Influence of Billet Temperature

Mr. Profile’s New Extrusion Line
Tapered heating and the “PYRAL” Integrated System
Taper Quenching: A Cost-Effective Tapering Method for Isothermal Extrusion
Induction Billet Heating – An Updated Summary of Latest Technology

Metallurgy

The Effect of Cooling Rate After Homogenization and Billet Preheating Practice on Extrudability and Section Properties of an Al-Mg-Si Alloy – Part 2: A Microstructural Investigation
Improved Properties of Extruded Products by Heat Treatment of AA6082 Alloy Sections
The Effect of Homogenizing Heat Treatment Practice on the Productivity of Al-Mg-Si System Alloy
Development of Structure, Recrystallization Kinetics and Prediction of Recrystallized Layer Thickness in Some Al-Alloys
Texture and Surface Grain Structure in Aluminum Sections
Extrusion with Active Friction Forces as an Innovation in Light Alloy Metallurgy
Co-Extrusion of Aluminum Laminar Composites From Billets with Mushy and Solid Phases
A Test Facility to Enable Study of Post-Extrusion Quenching for Production Distortion Control
Fine Powder P/M Extrusion Processing for Aluminum-Matrix Composites: Front Pad Extrusion Method
Observations on Production and Limit Diagrams for the Extrusion Process
Use of EBSD Technique for Microstructural Characterization of the Deformation Zone in Aluminum Extrusion
Flow Stress Parameters During the Extrusion of Aluminum Alloys
Future Perspectives on the Development of Alloy Composition and Processing for Extrusions
Temperature Distribution in Aluminum Extrusion Billets
Deformation Conditions of Steady Shaping of Internal Capillary-Ribbed Surface in Extruding Heat Pipes in Aluminum Alloys
Further Developments in the Extrusion of Aluminum-Based Metal Matrix Composites .
Constitutive Equations and Flow Stress Characterization Concepts for Aluminum Extrusion

Eqipment Design and Maintenance

New Technology in Extrusion Press Design
How to Obtain the Most from Your Ageing Ovens
The Maintenance of Extrusion Plant: Operating Extrusion Presses for Maximum Efficiency
Real-Time Maintenance Package: An Expert System for Automatic Hydraulic Fault Diagnostics Embedded in a Supervisory Computer
High-Temperature Textile Products for Aluminum Extrusion Handling Systems
A “No-Man” Extrusion Handling System
News on 2000’s Press Technology: “NBE” Burp Cycle
Improving Fixed Dummy Block Performance
The Ultimate Modernization
Extrusion Line for Big Profiles

Extrusion Cooling Processes

New Technologies for the Cooling and Quenching of Medium-to-Large Sized Aluminum Extrusions
Thermal Stretching of Aluminum Extrusions

Modeling

Computer Prediction of Extrusion Limit Diagrams
Microstructurally Based Modeling Applied to Cold Extrusion of Aluminum

Temperature

Noncontact Temperature Measurement of Aluminum: Its Design, Performance and Function on Aluminum Extrusion
Influence of Plastic Strain and Strain Rate on Temperature Rise in Aluminum Extrusion

Extrusion FEA

Application of the Finite-Element Technique to the Simulation of the Aluminum Extrusion Process
Simulation of Tube Extrusion in a Two-Dimensional, Axisymmetric Model . . . . . . .

Publish Only

Control Framework and Deformation Modeling of Extrusion Processes: An Upper Bound Approach
The Heat Balance During Multiple Press Cycles
Extrusion of Some Al-Li-Mg-Zr Alloys
Microstructural Evolution During Extrusion of Low Density Al-Alloys Prepared from Rapidly Solidified Powders
On the Relationship Between Extrusion Conditions and Fracture Toughness
Mathematical Computer-Aided Determination of Heating Processes in Aluminum Logs and Billets During Heating to Extrusion Temperature in Gas-Fired Billet Heaters
Extrusion with the Use of Active Friction Forces (EwAFF)

BILLET PROCESS AND EQUIPMENT

The Role of Modeling in the Design and Operation of Remelt and Casting Facilities

Modeling/Refractories/Equipment

Modeling Casthouse Operating Costs
Thermal Performance of Insulating Refractories for Casting Applications
Compact Type Remelt Plant with Horizontal DC Casting and Continuous Homogenization

Burners

A User’s Experience with Retrofitting an Aluminum Melting Furnace with Low NOx Regenerative Burners
Case History of an Aluminum Melter with Twinbed II (Regenerative) Low NOx Burners

Dross

Selection of THE PRESS Dross Processing System and the Results of Two Years of Operation
Inert Gas Dross Cooling (IGDC) – The New Standard

Metal Preparation

Molten Metal Quality Considerations for Aluminum Extrusion Ingot Product
Gains in Degassing System Designs Obtainable with Sialon Immersion Heating Technology
The Development and Performance Evaluation of a Dual-Stage Ceramic Foam Filtration System

Safety

Summary of Ten Years of Molten Aluminum Incident Reporting
Scrap Melting Safety for the Casthouse

Furnace Design

Remelt Aluminum Furnaces

Process Control and Technology

Augmented Water Exit Geometry for Billet Molds
Strategies for the Effective Application of Microbiological Control to Aluminum Casting Cooling Systems
Prevention of Cast Cracks in Al-Zn-Mg-Cu Alloy Castings
Precipitation of Mg2Si in Al-Mg-Si- Alloys During Cooling from Homogenization Temperature

Billet Processing

Performance of Secondary Versus Prime Billet
Structural Modifications Occurring During the Homogenization of Some 7XXX Alloys
Improved Operating Efficiencies of Log Homogenizing Furnaces
Band Saw for Billets: The Future

Water Quality

Consistent Water Quality for Aluminum Casting . . . an Important and Attainable Goal

VOLUME II – Brief Contents

Die Design and Technology
Applications and Product Innovations

DIE DESIGN AND TECHNOLOGY

Tribological Evaluation of Surface Treatments for Extrusion Dies

Die Technology

Application of Upper Bound Method to Extrusion Die Design
Accurate Temperature Measurements Inside the Tool in Hot Working of Metals
Metal Flow in Die Channels of Extrusion Investigated by an Experimental Grid Pattern Technique

Computer Design

The Computer-Aided Design and Computer-Aided Manufacture of Extrusion Dies
A 3D Feature-Based Computer Support Tool for the Design of Aluminum Extrusion Tool Assemblies

Finite Element Analysis

Automatic Bearing Length Assignment Using the Medial Axis Transform
Simulation of Aluminum Extrusion Based on a Finite Element Method (FEM )
Analysis of Metal Flow in Weld Pocket Dies
Numerical Simulations in Extrusion Die Design
Effect of Blend and Extrusion Parameters on Material Flow

Weld Quality

Transverse Weld Defects

Bearings and Metal Flow

A Modified Classification System for Metal Flow Adapted to Unlubricated Hot Extrusion of Aluminum and Aluminum Alloys
An Experimental and Numerical Investigation of the Thermo-Mechanical Conditions on the Bearing Surface of Extrusion Dies
Studies of Dead Metal Zone Formation in Aluminum Extrusion
Metal Flow in Two-Hole Extrusion

Bearing Surfaces

Interface Mechanisms on the Bearing Surface in Extrusion
Housing of Ceramic Die Inserts for Aluminum Extrusion
Metal Flow and Temperatures Developed During Direct Extrusion of AA2024
Direct Extrusion of AA6060 Through Dies with Coated Bearing Lengths

Die Design Systems

System to Calculate Chambers and Feeds to Obtain an Extrusion Die Designed, Manufactured, and Produced with One Single Minimum Bearing. Tests Results and Results as Reported by Licensees. Present Status
The Use of a Planning System to Support the Design of Extrusion Dies – Rapid Determination of Bearing Lengths
Design of Hollow Dies for Manufacturing Thin-Walled Hollow Sections
Analysis of the Deformations that are Active on the Webs of Hollow Dies during the Extrusion Cycle. Analysis Conducted by Finite Elements

Die Treatments

Ion Nitriding of H.13 Extrusion Dies Using the Pulsed Plasma Technique
The Heat Treatment of Extrusion Tools Using Fluidized Bed
A Review of the Surface Modification Techniques for Pre-Heat-Treated H.13 Extrusion Dies and Emerging Technologies
Surface Enhancement Technology for Metal Extrusion

Hollow Dies and Special Die Designs

Advanced Design and Manufacture of Hollow Dies or Improved Extrusion Speeds
Extrusion Welding in Porthole Die Extrusion
Determination of Parameters Required for Joining Process in Hollow Dies
Convex Dies for Aluminum Extrusion

Coatings/Finite Element Analysis

Plasma Sprayed Ceramic Coatings for Extrusion Dies
Application of Upper Bound Element Technique (UBET) for Aluminum Extrusion

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Influence of Die Handling Operations on Performance of Nitrided Aluminum Extrusion Dies
An Industry Update on the Use of Abrasive Flow Machining for Exrusion Die Polishing

APPLICATIONS AND PRODUCT INNOVATIONS

An Architect’s Perspective on Aluminum

Automotive

Designing for Tomorrow’s Customer Needs – An Electric Vehicle Charger
Bending of Aluminum Extrusions for Automotive Applications: A Commentary on Practical and Theoretical Aspects
Aluminum Spaceframe Technology Applied to the Development of a Low Investment Electric Vehicle Prototype

Alloys/Bridges and Structures/Extrusion Packaging

Extrudability and Mechanical Properties of Some 7XXX-Series Alloys
Aluminum Alloys for Bridges and Bridge Decks
New Rules for Determining the Strength of Extruded Shapes
Automatic Packaging and Handling of Aluminum Extrusions-Extruders Needs and Customers Requests

TPM/Innovative Product Development

Improving Equipment Effectiveness Through Total Productive Manufacturing
How to Use Aluminum Price Volatility When Developing a Product
Aluminum Service Centers – Your Opportunity for Profitable Growth
Aluminum Extrusion House in Fort Pierce, Florida

Finishing

The “Zero Discharge” Anodizing Line
Mechanical Etching of Aluminum Sections Prior to Anodizing, Painting or Powder Coating
Chrome Free Pretreatment: A Cost Effective Solution to the Elimination of Environmental and Workplace Concerns Surrounding Chromium
Novel Siloxane Coatings to Meet Changing Environmental Regulation and High Performance Requirements of Quality Aluminum Extrusions . . .

Innovative Business Practices

Service Centers: A Channel to Quality Oriented Customers!
Today’s Users’ Expectations of Extruders: Quality, Service, Partnership
Continuous Quality Improvement Attaining ISO-9002 Certification
EDI – Why Should I Be Interested?

Welding and Brazing

Production of Wide Aluminum Profiles by Solid-State Friction Stir Welding
Cost Saving by Aluminum Robotic Welding
New Bending Process for Aluminum Alloy Extruded Shape by Pulse YAG Laser Welding
Controlled Atmosphere Brazing of Aluminum Automotive Heat Exchangers

Quality

Visual Quality Attributes of Aluminum Extrusions

Processing/Training Methods

Computer-Aided Design of Industrial Bending Processes for Aluminum Extrusions
Fiber Abrasive Finishing Systems for End-Deburring Extruded Aluminum Profiles
Aluminum: Different? Yes. Difficult? No. When You Know How

Advanced Technology

New Extrusions for Building Construction Connections
Opportunities and Pitfalls to Combine Aluminum Extrusions with High-Pressure Die Castings
The Concept of Becoming a User/Extruder
Improvement of Surface Hardening for Aluminum Extrusion Products

Conform

Development of Conform Technology for the Manufacture of Multi-Port Tube
Simulation and Analysis of Deformation in Conform Extrusion

Miscellaneous

Profiles of Change in India
Secondary Aluminum MACT Development

Product Liability

The Role of Sales in Product Liability Loss Prevention

Publish Only

Managing the Human Side of a Press Installation or Modernization Project